Lightweight Design. Lightweight Design in education Examples and experiences at IPEK. IPEK Institut für Produktentwicklung. 1 TT.MM.

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1 Lightweight Design in education Examples and experiences at IPEK IPEK Institut für Produktentwicklung Modellbildung 1 TT.MM.JJJJ KIT Universität des Landes Baden-Württemberg und nationales Forschungszentrum in der Helmholtz-Gemeinschaft

2 Learning Objectives of the lecture A comprehensive introduction to the fundamentals of lightweight design Focus on the aspect of lightweight design Establishing a sound understanding of the classic and modern lightweight principles as well as the relevant constructive and virtual tools Lightweight design in the scope of the product development process and the associated complex relations Introduction of the methods of lightweight design Lightweight design from a practical perspective by guest lecturers 2 TT.MM.JJJJ

3 Guest Lectures The Electromagnetic Pulse Technology (EMPT) in industrial application Joining, welding, forming as if guided by an invisible hand Virtual product development in the context of lightweight design Picture source: 3 TT.MM.JJJJ

4 Organisational information Classification of the lecture (2 Swh / 4 CP, Nr ) Diploma: elective, core or supplementary subject, part of main subjects Bachelor/Master: core subject/ supplementary subject Examination Oral No additional material allowed Time limit: min. Further information regarding exam dates during the course of the lecture! Lecture slides: available online 4 TT.MM.JJJJ

5 Introduction Motives for lightweight design Definition of lightweight design Milestones of lightweight design Range of applications and examples Trends in lightweight design The fields of tension 5 TT.MM.JJJJ

6 Motives for the lightweight design Energy and material efficiency of accelerated and moved mass Optimal material and energy efficiency in compliance with economic and ecological requirements Under guarantee of fulfilling functions Effects of weight reduction Increase of payload or velocity Lower resistance of rolling, acceleration and ascents Lower energy consumption Lightweight design is not self-perpetuating! Cost-benefit-ratio 6 TT.MM.JJJJ

7 Motives for lightweight design Example: Lightweight design is not self-perpetuating! Lightweight design is expensive Carbon is considerably lighter than Steel, but costs 5.7 times more in automobile manufacturing 570 Weight: Steel = 100 Price: Steel = Source: ADAC Motorwelt, 4/2012 mit Quellverweis Zeitschrift Capital, SGL Group 7 TT.MM.JJJJ

8 Motives for the lightweight design SAMPE presented Innovation Award 2011 to IPEK-Diplomanden David Roquette 1.5 kg light racing rim made of CFRP* *Result of a cooperation project between IPEK und KA-RaceIng 8 TT.MM.JJJJ

9 Motives for the lightweight design Development of vehicle weight on the example of VW-Golf Reversal of the weight spiral is essential! year Golf VII 2012 Golf I +400 kg Source: Auto Bild kg 1150 kg Mass comfort, security, performance, legislation, low emission, 9 TT.MM.JJJJ

10 Motives for the lightweight design Ecological aspects 10 TT.MM.JJJJ

11 Motives for the lightweight design Ecological aspects: Lightweight design materials in wind power system Source: SGLROTEC 11 TT.MM.JJJJ

12 Motives for the lightweight design Economic aspects / saved kg amount/ year Source: Klein 12 TT.MM.JJJJ

13 Introduction Motives for the lightweight design Definition lightweight design Milestones of lightweight design Range of application and examples Trends in lightweight design The fields of tension 13 TT.MM.JJJJ

14 Definition of lightweight design The task of lightweight design is to reduce the weight of technical constructions. [ ] to spread the load on the whole construction as evenly as possible, to use the allowable stresses broadly and evenly and to enable the available space to carry larger load capacity and higher stiffness. (Schapitz, 1963) [ ] minimizing the weight without cutting the allowable load capacity or other functions of the construction (Wiedemann, 2007) Lightweight design is a interdisciplinary engineering science which is based on the knowledge of strength theory, computing technology, material science and manufacturing engineering. (Klein, 2007) 14 TT.MM.JJJJ

15 Definition of lightweight design Lightweight design is a comprehensive construction principle which follows the goal to reduce the weight and the mass respectively. (Degischer & Lüftl, 2009) Lightweight design is a development strategy (agent system) which aims to realize a required function (target system) with a system minimized mass under predefined boundary conditions (object system). Lightweight design is generally not self-perpetuating, but has to be justified with superior goals cost and benefits (Albers, 2009) 15 TT.MM.JJJJ

16 Introduction Motives for the lightweight design Definition lightweight design Milestones of lightweight design Range of application and examples Trends in lightweight design The fields of tension 16 TT.MM.JJJJ

17 Milestones of lightweight design Theoretical foundation goes back to C. Maxwell (1869) and A. Michell (1904) Principles for optimal paths of forces in minimum volume Key issues in lightweight design were first brought up and dealt with systematically in the aircraft industry Aircraft research played a decisive role in lightweight design General expanding of theoretical basics Newly tested design principles (Source: Wiedemann, 2006) 17 TT.MM.JJJJ

18 Milestones of lightweight design Replacing the lattice structure with self-supporting design using the load-carrying capacities of the hull structure Developing full panel and shell systems First in aircraft, then: Railway wagon construction Ship construction Vehicle body construction Source: Klein 18 TT.MM.JJJJ

19 Milestones of lightweight design Material closure by welding technology No material doubling such as when using rivet joints Welding joints with high strength New design possibilities Developing new structural concepts cover plate rivet joint bonded stringer rib plate Source: Klein 19 TT.MM.JJJJ

20 Milestones of lightweight design Progresses in Material Science lead to new ways of construction New high performance materials Metal and polymer composite material High functional integration of extreme stiffness and minimal weight Source: Specialized Source: IPF, Dresden Source: Renault F1 20 TT.MM.JJJJ

21 Milestones of lightweight design Computer-aided design and construction Computer-aided design(cad) Computer-aided development (CAE) Product simulation (FEM) Structure optimization (FEM) Working condition development of a designer Past today future 21 TT.MM.JJJJ

22 Milestones of lightweight design Development and application of virtual product development Efficient electronic data handling technology Extensive analyses of loading and deformation performance with Finite-Element-Methode (FEM) possible Enables posibillities of optimization concerning a better aptitude for lightweight design Source: KA-RaceIng 22 TT.MM.JJJJ

23 Introduction Motives for the lightweight design Definition lightweight design Milestones of lightweight design Range of application and examples Trends in lightweight design The fields of tension 23 TT.MM.JJJJ

24 Range of application Aerospace Racing Vehicle and commercial vehicle Plant construction Railway vehicle construction Boats and ship construction Architecture Wind energy facilities Sport equipment & free time industry Automation und Robotics Medical engineering Furniture industry 24 TT.MM.JJJJ

25 Range of application Potential to economize materials in manufacturing industry share of companies material saving potential 25 TT.MM.JJJJ

26 Range of application Total potential to economize materials in the manufacturing industry 26 TT.MM.JJJJ

27 Range of application Example from aerospace engineering Source: EADS 27 TT.MM.JJJJ

28 Range of application Example from aerospace engineering Glare (Glass fibre reinforced Aluminium) New type of composite material Layers consist of aluminium and a glass fibre laminate by turns Features Better burn-through and impact performance Application on the trunk body, on the downside of the wings, on nose area of vertical stabilisers and on cockpit areas Good performance against cracks Price is about six times higher than von aluminium More difficult to handle than aluminium (assembly, handling, processing) 28 TT.MM.JJJJ

29 Range of application Example from vehicle construction High strengh aluminium profile for spaceframe First generation of luxury class Audi A8 with aluminium body in 1994 Source: Audi 29 TT.MM.JJJJ

30 Range of application Example from vehicle construction Stirring cross member from magnesium conventional steel design light weight design front view front view weight: 10.6 kg weight: 5.8 kg Source: Opel weight reduction: 4.8 kg 30 TT.MM.JJJJ

31 Range of application Example from vehicle construction Seat shell from steel Welded from 5 single parts Seat shell from fiber reinforced plastic composites Integral pressed component Weight reduction of ca. 45 % under equal production costs Source: TU Dresden 31 TT.MM.JJJJ

32 Range of application Example from racing Formula Student (KA-RaceIng) composites stirring wheel (CFRP) panel (lasersintering) Source: KA-RaceIng wheel hub(alu) rims (CFRP) pedal-box (Alu) wheel carrier (steel) 32 TT.MM.JJJJ

33 Range of application Example for ship construction Drive shaft of ship from fiber reinforced composite Gewichtsersparnis 40 % Source: Tenax-Fibres 33 TT.MM.JJJJ

34 Introduction Motives for the lightweight design Definition lightweight design Milestones of lightweight design Range of application and examples Trends in lightweight design The fields of tension 34 TT.MM.JJJJ

35 Trends in lightweight design Aerospace multifunctional materials fiber comp. material metal wood Source: EADS 35 TT.MM.JJJJ

36 Trends in lightweight design High-tech products which are resource efficient and ecologically friendly Load case adapted construction with tailored material properties Multi-Material-Design (mixed construction) Intelligent lightweight design active elements (transductors) Material systems become adaptable to external load case. Adaptronic Integrated sensors Source: TU Dresden 36 TT.MM.JJJJ

37 Introduction Motives for the lightweight design Definition lightweight design Milestones of lightweight design Range of application and examples Trends in lightweight design The fields of tension 37 TT.MM.JJJJ

38 Fields of tension Global Trends Availability of fossil fuels and fuel prices Urbanization Demographic change Regionale Regelungen Political interests Legal regulations Government aid Costumer expectations Reduced emissionen No abdication of comfort and safety Availability of electric vehicles in the near future Source: Aachen Kolloquium 2009, M. Dick 38 TT.MM.JJJJ

39 Fields of conflicts: Complexity lightweight design Increase in complexity Electric network in the automotive vehicle Sourcen: ATZ-2001, BMW 39 TT.MM.JJJJ

40 Fields of conflicts: Acoustic (comfort) Dynamic forces during operation can cause inadmissible oscillations and respectively eigen frequencies or high airborne radiation. ωω = cc mm = cc ρρ VV ; ωω = 2ππff Constructive measures: Increase in stiffness (Design like shape, connection method or force transmission, material) Optimized distribution of material, if needed additional mass, in order to shift eigenfrequencies Damping by application of damping materials 40 TT.MM.JJJJ

41 Fields of conflicts: Acoustic (comfort) hood (measured with 3D-scanning-vibrometer) with CM electrical CM: combustion engine Man-Machine-Interaction Vibrations of stirring wheel Acoustics (internal space) 41 TT.MM.JJJJ

42 Fields of conflicts: Electromobility Energy density of different energy carriers for automotive applications Unit MJ/kg 45,4 43,0 In order to store an equal amount of energy electric energy carriers are significantly heavier and bigger than liquid energy carriers. 0,9 0,11 Diesel Gasoline (Otto) Li-Ion Battery Lead battery 42 TT.MM.JJJJ

43 Fields of conflicts: Electromobility Example: Omnibus Citaro FuelCell Hybrid 43 TT.MM.JJJJ

44 Fields of conflicts: Electromobility High-voltage-energy storage requires additional safety measures: Activation of vehicle Load cases in case of crash Can all safety relevant requirements be fulfilled optimally? Are the crash load cases sufficient for the dimensioning of electric vehicles? Are new safety standards necessary? 44 TT.MM.JJJJ

45 Fields of conflicts: Safety Application of lightweight materials e.g. as crash-absorber CFRP in premium class vehicles Simulation of CFRP-failure mechanisms e.g. for crash load case 45 TT.MM.JJJJ

46 Fields of conflicts: Safety Suitable efficiency analysis necessary Application boundaries critical for CFRP for unsuspended mass due to failure mechanisms Application range very restricted: CFRP-rim of Formula Student Team KA-RaceIng 46 TT.MM.JJJJ

47 Fields of conflicts: Production Restrictions for optimization due to manufacturing Established approach for metallic structures: Optimization of topology with demoulding properties for casting materials Bending beam Without demoulding With demoulding Beading with automated testing of formability developped at IPEK ManuBeadOpt (Manufacturing based Bead Optimization) Oil pan stiffened formable Restrictions caused by manufacturing of anisotropic material are considered but haven t reached completeness 47 TT.MM.JJJJ

48 Fields of conflicts: multidisciplinary optimization System-based optimization (Multidisciplinary optimization - MDO) Shape optimization for product lifecycle Acoustics based shape optimization Robustness Stiffening methods for thin-walled structures: ribbing/ sandwich/ beading 48 TT.MM.JJJJ

49 Fields of conflicts: Customer requirements Example: Convertible vehicle BWM series 1 (123d) BWM series 1 Convertible (123d) Fuel usage (combined) Weight: 1495 kg Weight: 1615 kg +120 kg 5.1 l/100km 5.3 l/100km Stiffness, safety Picture source: BMW Produktkatalog, Source: BMW Technische Daten 49 TT.MM.JJJJ

50 Fields of conflicts: Recycling Recycling-philosophy Reduction of material diversity opposed to trend of mixed construction Demounting and recycling concepts for multi-material design and adhesive joints Methods for coupling of product development and recycling process 50 TT.MM.JJJJ